I3500 Instruction Manual PDF

55M3500JBE00 Rev B
i3500 Crane information center

Rated Capacity Indicator System for Telescopic
Cranes Pressure Sensing, Multi-Point Version
Instruction Manual
Ref: LD October 2010 Ref: A.A
Wylie Systems Rayco Electronic Systems Wylie Systems

(Rayco Technology Group) (Rayco Technology Group) (Rayco Technology Group)
1020 9th Avenue SW 2440 Dalton Avenue Drury Lane

Suite 124 Ste-Foy, Qc St-Leonards on Sea, East Sussex
Bessemer, AL CANADA ENGLAND
USA 35022 G1P 3X1 TN38 9BA
Tel: (205) 481-2080 Tel: (418) 266-6600 Tel: (+44) 1-424-421235

Fax: (205) 481-2081 Fax: (418) 266-6610 Fax: (+44) 1-424-433760
Copyright © 2010
RaycoWylie Systems
All rights reserved.
This page has been intentionally left blank
i3500 Introduction
Rayco Wylie Systems

EC Declaration of Conformity
Product type: i3500 Rated Capacity Indicator
Authorised Representative: Wylie Systems Manufacturer :

Drury Lane Rayco Electronic Systems
St Leonards-on-sea 2440 Av Dalton
East Sussex , United Kingdom Québec, PQ, Canada
TN38 9BA G1P 3X1
Is in conformity with: The provisions of the Machinery Directive (Directive 2006/42/EC)

The provisions of the Electromagnetic compatibility Directive (Directive
2004/108/EC)
This conformity is supposed referring to the following standards,

documents and requirements:
EN 13000 Cranes – Mobile Cranes

EN 12077-2 Cranes Safety, limiting and indicating devices
EN 954-1 Safety and related parts of control systems.
Category 2
EN 60204-32 Safety of machinery. Electrical equipment of machine
Requirement for hoisting machine
EN 61000-6-2 Electromagnetic compatibility - immunity
EN 61000-6-4 Electromagnetic compatibility - emission
For and on behalf of Wylie Systems, a division of

RaycoWylie Systems:
………………………………………………
Luc Patry
RaycoWylie Quality & Certification Manager ISO9001:2008 FM 33972
December 23, 2009
This document is also the certificate of origin. The product is manufactured in more than one country and all European
Union import duties and taxes have been paid in the United Kingdom.
www.raycowylie.com
Telescopic Cranes Pressure Sensing 4 Instruction Manual

i3500 Introduction
The purpose of this manual is to provide the customer with the operating
procedures essential for the promotion of proper machine operation for its
intended use. The importance of proper usage cannot be overstressed. All
information in this manual should be read and understood before any attempt is
made to operate the machine.
Since the manufacturer has no direct control over machine application and
operation, conformance with good safety practice in this area is the responsibility
of the user and his operating personnel.
All procedures herein are based on the use of the system under proper operating
conditions, with no deviations from the original design. Alteration and/or
modification of the equipment are strictly forbidden without written approval from
RaycoWylie Systems.
The i3500 RaycoWylie Systems Crane Information Center must be regarded

only as an aid to the operator. When the parameters are set correctly, the
indicator will warn the crane operator of an approaching overload condition that
could cause damage to equipment, property, and/or injury to the operator or site
workers in the vicinity of the crane and its load.
This system must never be used, under any circumstances, as a substitute for the
good judgment of a crane operator when carrying out approved crane-operating
procedures. Responsibility for the safe operation of the crane lies with the crane
operator. The indicator equipment will not necessarily prevent crane damage due
to overloading and related causes if not set properly.
Before operating a crane equipped with a RaycoWylie system RCI, the

operator must carefully read the information in both this manual and the crane
manufacturer operator’s manual. He must also be aware of all the federal, state
and local safety standard and regulations applicable to his job. Correct functioning
of the system depends upon routine daily inspection.
Any suspected faults or apparent damage should be immediately reported to the
responsible authority before using the crane.
Telescopic Cranes Pressure Sensing I Instruction Manual

i3500 Introduction
Since safety of personnel and proper use of the machine is of primary concern,
different symbols are used throughout this manual to emphasize certain areas.
The following definitions indicate the level of hazard when these symbols appear
throughout this manual. Whenever one of these symbols appears in this manual,
personnel safety is a concern. Please take time to read and understand these
definitions!
DANGER: INDICATES A POTENTIALLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN DEATH OR SERIOUS INJURY.
CAUTION: INDICATES A POTENTIALLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN
MINOR OR MODERATE INJURY. IT MAY ALSO BE USED
TO ALERT AGAINST UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION THAT MAY CAUSE

MACHINE DAMAGE IF NOT CORRECTLY FOLLOWED.
NOTE: PROVIDES INFORMATION THAT MAY BE OF

SPECIAL INTEREST.
Telescopic Cranes Pressure Sensing II Instruction Manual

i3500 Introduction
TABLE OF CONTENTS
EC Declaration of conformity
Warnings
1- GENERAL DESCRIPTION OF THE SYSTEM

1.1 Introduction page 4
1.2 Personnel qualification page 4
1.3 Intented use of the I3500 System page 4
1.4 Brief description of the I3500 System page 5
1.5 Typical Components Location & Description page 9
1.6 Block Diagram page 10
1.7 Technical Data page 11

2- DETAILED DESCRIPTION OF THE DISPLAY UNIT
2.1 Normal Mode Display (default screen) page 12
2.2 Display Buttons Location and Purpose page 13
2.3 Warning Lights and Indicators Location page 15
2.4 Warning Lights and Indicators Detailed Description page 16
3- INSTALLATION & CALIBRATION
4- OPERATING INSTRUCTIONS
4.1 Safety Instructions page 19
4.2 Residual Risks page 20
4.3 Power On page 21
4.3 System configuration page 21
4.4.1- Duty Number Selection page 22
4.4.2- Hoist Selection page 24
4.4.3- Parts of Line Selection page 25
4.4.4- System Test page 27
4.4.5- System Configuration Information Screen page 28
4.4.6- System Setup page 29

i3500 Introduction
TABLE OF CONTENTS
4.4.6.1- Language Selection page 30

4.4.6.2- Units Selection page 31
4.4.6.3- Reverse Video page 32
4.4.7- Bypass/ Rigging page 32
4.4.7.1- Rigging Mode page 33
4.4.7.2- Overload Override (bypass) page 34
4.4.7.3- ATB Condition Override page 34
4.4.8- Bridging & Range Limiting Box page 35
4.4.8- Bridging Device page 35
4.4.8.2- Bypass Rigging using the range limiting box page 37
4.5 Operational Limits page 38
4.5.1- Accessing the Limits Mode page 39
4.5.2- Limit value Adjustments page 40
4.5.3- Enable / Disable a limit page 41
4.6 Range Limiting Option page 42
4.6.1- Accessing Range Limiting Mode page 44
4.6.2- Limit high page 45
4.6.3- Free Zone page 46
4.6.4- Variable Limit Height page 47
4.6.5- Variable Limit Radius page 48
5- DIAGNOSTIC & TROUBLESHOOTING
5.1 Diagnostic Menu page 50

5.2 Angle/Lenght Sensor page 51
5.3 Pressure Sensor page 53
5.4- Relays page 53
5.5 Slew Sensors page 55
5.6 Detected adresses page 55
5.7 Error Messages and the Use of the ‘‘ ? ’’ key page 56
5.7.1 Internal Peripherals page 56
5.7.2 External Peripherals page 59

i3500 Introduction
6- INSPECTION TESTING & MAINTENANCE
6.1- Frequent Inspections page 63

6.2- Periodical Inspections page 63
6.3- Rated Load test page 64
6.4- Maintenance page 65
6.5- Maintenance Procedure page 66
6.6- Adjustements & Repairs page 67

i3500 Introduction
-1-
General Description of the System
1.1 Introduction
This manual contains Operation, Troubleshooting and Maintenance

information for the i3500 system. When using i3500 system, always observe
the safety rules and regulations applicable in the country of operation to reduce
the risk of personal injury or damage to the equipment. Each safety instruction
throughout this manual must be taken into consideration when using the
i3500 system. The information contained in this manual will enable qualified
personnel to properly operate and efficiently perform maintenance.
1.2 Personnel qualification
The i3500 system shall be operated only by personnel without limitations in the
physical abilities of the upper limbs and no visual or hearing impairment, who
have completed all operator trainee qualification requirements and have read
and fully understood the instructions in this manual. Operator requirements
shall include: demonstrating the ability to read, write and comprehend and use
arithmetics and read and understand the load / capacity charts in the language
of the crane manufacturer’s operating instruction materials. Maintenance of
the system is intended only for fully qualified and trained personnel for this task.
1.3 Intended use
The i3500 system is intended to provide a valuable aid to the crane operator
by indicating all relevant parameters typically shown on the duty chart of the
crane. The i3500 system shall prevent the crane from supporting a load outside
the limits of the permitted radii and outside the loads shown and described on
the rated capacity chart or the permissible working load of the ropes when set
and operated correctly.

i3500 Introduction
1.4 Brief description of the i3500 System
The i3500 is a computerized crane monitoring system, designed as an operator

aid. It comprises sensors fitted to the crane and a display located in the cabin of
the crane. This version measures the boom cylinder pressure, the boom angle
and length, and it indicates safe or critical conditions, while performing an
authorized lift of loads. Optional sensors may also be fitted to monitor the slew
angle and the rotation of the hoist drum to provide some extra information to
the operator.
All the sensors are linked through a single CANbus (Controlled Area Network).
The pressure sensors provide electrical signals that are proportional to the
actual pressures in the hydraulic boom cylinder system of the crane. An
inclinometer provides a signal that is proportional to the boom angle and a
reeling drum provides a signal that is proportional to the boom extension. The
radius and the load are calculated from these signals with the dimensional
crane data preprogrammed in the i3500 system.
During operation the load lifted by the crane is calculated from the measured
boom cylinder pressure and is automatically compared with corresponding
data related to the maximum permissible crane loading.
The actual load is expressed as a percentage of the permitted load (% SWL).
If this percentage exceeds a preset value, alarms and safety functions are
activated. The values of the hook load, the permissible load, the main boom
angle and the radius are displayed in a digital form on a graphic liquid crystal
display (LCD).
If the additional sensors are fitted, then some information about the current
slew angle and the hook height will also be available. The required crane duty
charts are stored in a non-volatile memory and can only be modified with
the approval of the crane manufacturer. The calculated crane parameters
and calibration data are stored in an additional non-volatile memory. The
calibration of the system is performed only with the use of known loads, boom
angles, and other pre-determined data.
Audible alarms
An intermittent buzzer located in the i35000 system display warns the crane
operator to take specific course of actions at the approach of the rated capacity.
The threshold of the approach alarm has been fixed at 95% of the rated capacity.
The buzzer will alert in a continuous way when the rated capacity is reached
or exceeded (≥ 100%). Personnel in the danger zone are warned by an external
buzzer so that they can get out danger when the rated capacity limiter is
activated or overridden.
(Continues on next page).
i3500 Introduction
The crane operator will also be warned by the audible alarm when the
operational limits or the range limiting function is activated and a selected
limit is reached. See Table (1) for more details on audible signal operation.
When wearing ear protection safety devices or

if using music earphones during crane operations,
make sure that they will not impair your ability
to hear the audible warning signals while operating
the i3500 system.
Visual alarms
The display of the i3500 system has been equipped with up to 3 warning lights
to warn the operator and signal for a specific course of action. A yellow light
will blink along with the audible alarm at the threshold point of the approach
alarm (at 95%) of the rated capacity (100%).
A red light will illuminate when the rated capacity has been reached or exceeded.
An additional red light will also turn on when the rated capacity limiter is
activated (Cut Off).
External visual alarms are also provided with the external audible alarm to
warn the personnel in the danger zone so that they can be aware of the danger
when the rated capacity limiter is activated or overridden. Note that depending
on system configuration, your system may be equipped with one or with three
external lights. See tables 1 and 2 for external visual alarm operation.

i3500 Introduction
System with 3 warning lights

Table 1
Display External
Ext Green Amber Red

Event Approach Overload Cut Audible
Buzzer Light Light light
No event Off Off Off Off Off On Off Off

Approach
to SWL Blinking Off Off Intermittent Off Off On Off
(Alarm 1)
Overload
On On Off Continuous On Off Off On
(Alarm 2)
Motion cut
On On On Continuous On Off Off On
(Alarm 3)
Not calibrated On On On Continuous On Off Off On
Setup button
activated
within
working
X X X X On Off On On
range
deadlock
> 100 - 110%
override
Boom up
X X X X On Off Off On
override
Bridging Key X X X X On Off Off On
A2B operating
X X On Continuous Off On Off Off
mode
A2B
(Calibration
X X X Off Off Off On Off
or Rigging
mode)
Setup button
activated
in Erection/
Off Off Off Off Off Off On On
Rigging to
override the
A2B
Calibration
Off Off Off Off Off Off On Off
mode
Range
Limiting On Off Off Intermittent Off Off On Off
approach
Range
limiting On On On Continuous On Off Off On
limit reached
Rigging mode Off Off Off Off Off Off On Off

i3500 Introduction
System with 1 warning light

Table 2
Display External
Ext. Red
Event Approach Overload Cut Audible
Buzzer light
No event Off Off Off Off Off Off

Approach
to SWL Blinking Off Off Intermittent Off Off
(Alarm 1)
Overload
On On Off Continuous On On
(Alarm 2)
Motion cut
On On On Continous On On
(Alarm 3)
Not calibrated On On On Continous On On
Setup button
activated
within
working
X X X X On On
range
deadlock
> 100 - 110%
override
Boom up
X X X X On On
override
Bridging Key X X X X On On
A2B X X X X Off Off
Setup button
activated
in Erection/
Off Off Off Off On On
Rigging to
override the
A2B
Calibration
Off Off Off Off Off Off
mode
Range
Limiting On Off Off Intermittent Off Off
approach
Range
limiting On On On Continuous On On
limit reached
Rigging mode Off Off Off Off Off Off

i3500 Introduction
1.5 Typical component location and description
1) i3500 display box: It is also the central processing unit (CPU) of the
i3500 system. Its principal feature is a CANBUS communication interface
and graphical LCD screen.
2) Angle sensor: A solid state angle sensor that is used to monitor the
angle of the boom.
3) Pressure sensors: Highly sensitive, built for precise lifting and

weighing in harsh environments.
4) Cable reel with angle and length sensor: A solid state angle sensor is
used to monitor the angle of the boom. A potentiometer is used to monitor
the boom length.
5) Anti-two block: the anti-two block switch is normally closed (with

weight hanging) spring-loaded switch (option).
6) Wind speed sensor: Shows wind speed value on the display (option).

i3500 Introduction
1.6 Block Diagram
Block Diagram of the i3500 CANbus

Communication Link Network.

i3500 Introduction
1.7 Technical Data
Accuracy: In accordance with SAE J159 or EN13000

Operating temperature: -20 ºC to + 60 ºC
Supply voltage: 10.2 to 36 VDC (maximum rating)
Display size: 6.25’’ x 8.5’’ x 3’’ (15cm x 21cm x 7.5cm)
Display sealing: IP65
Memory capacity: 10.000 load/radius curves
CANbus sensors / interface: Default quantity Maximal quantity

- Load or pressure sensor 2 6
- Angle, Length sensor 1 5
- Relay output 5 32
- Digital input 4 16
- Provision for other sensors
Peripheral communication port RS-232

i3500 Introduction
-2-
Detailed description of the display unit
2.1 Normal Mode Display (default screen)
SLEW PARTS BOOM TIP DUTY

ANGLE OF LINE HEIGHT NUMBER
(FALLS)
BOOM
LENGTH
HOIST:
M:MAIN
A:AUXILIARY
PARTIAL DUTY BOOM ANGLE OPERATING HOOK LOAD SAFE

DESCRIPTION RADIUS WORKING
(TOGGLE WITH LOAD
BUTTON #4) (S.W.L)
(RATED
CAPACITY)
The display should be used only as a guide, NOT as an

indication that the crane would or would not pass under a
structure of an accurately known height.
The slew angle indicator (upper left corner of the screen)

is only present when the range limiting option is installed
in the machine.

i3500 Introduction
2.2 Display Buttons Location and Purpose
i3500 DISPLAY BOX OVERVIEW
WARNING
LIGHTS
GRAPHICAL
DISPLAY
INTERNAL
BUZER
OPERATING
BUTTONS
OPERATING BUTTONS PRESENTATION
MODE BUTTON
Shows system’s modes. Press this button to choose
one of these operating modes:
-Normal mode
-System Set Up mode
-Diagnostic mode
-Calibration mode (password protected).
HOIST / SCROLL UP BUTTON

Shows hoist menu for selection of the hoist currently
in use. Also used to scroll up through options or to
increase adjustable values.
PARTS / SCROLL DOWN BUTTON

Shows parts of line (falls) menu for selection of the
number of parts currently in use. Also used to scroll
down through options or to decrease adjustable values.

i3500 Introduction
SELECT BUTTON
Used to select a highlighted item in a menu. In
normal mode, use this button to select the infor-
mation displayed in one of the pull-down menus.
If no menu is opened, used to scroll through the
configuration at the bottom line of the display.
ESCAPE BUTTON
Used to close a menu or to cancel the modification of a
value. Push it several times to return to normal mode.
HELP BUTTON
This button will show the problem source when a fault
is detected by the system. Press it to see the description
of the problem.
DUTY BUTTON
Shows the menu for the selection of the duty by
number or by crane configuration. Press this button
to enable the selection of crane parameters like the
boom length, the head type and the counterweight, (if
available).
INFO BUTTON
Shows all the information regarding the current crane
configuration. Press it a second time to access the
operating system’s information screen and a third
time to see the data logger screen (option).
BYPASS/ RIGGING BUTTON

Used to enter the rigging mode. (See sections 4.4.7 &
4.4.7.1 for complete details)
TARE BUTTON
Toggles the load display between the actual load
and the tared load.
TEST FUNCTION (Buttons 9 & 10)

Press them simultaneously at any time during normal
operation, to check the functioning of the warnings
(without the need to lift a load), keypad, relays or display.
Note: The crane must not be in overload condition.

i3500 Introduction
2.2 Warning Lights and Indicators Location
APPROACH OVERLOAD MOTION

WARNING WARNING CUT
(YELLOW LIGHT) (RED LIGHT) (RED LIGHT)
PRESET LIMIT(S)
REACHED
TWO-BLOCK RATED CAPACITY

CONDITION LIMITED BY THE
DETECTED HOIST ROPE

i3500 Introduction
2.3 Warning Lights and Indicators Detailed Description
The approach warning light blinks when the load on the

hook is between 90% and 99.9% of the rated capacity
(adjustable value; EN13000:2010: 90% and 97.5% ).
This is accompanied by an audible warning device
that is fitted inside the display unit. This light
(yellow in color) will also flash on and off if you are
approaching within 5 units (feet, meters or degrees) of
a predetermined limit (set in the limits setting mode).
Operate with caution !

The crane is working near its
maximum operating capacity.
The overload warning light (red in color) illuminates at

or above 100% of the rated capacity. This light will also
turn on if you are reaching a predetermined limit (set
in the limits setting mode).
The crane’s maximum capacity has

been reached or exceeded.
The motion cut warning light (red in color) illuminates

at or above 100.1% of the rated capacity. This is
usually associated with, for example, booming down,
telescoping out or hoisting up. The exact operation is
specific to the crane model.
The crane has exceeded safe

operational ratings and is now in an
unsafe condition. Hoist up, telescope
out and boom down functions will be
stopped if a motion cut solenoid is
connected to the system.

i3500 Introduction
The Rope Limit indicator appears just above the

number of parts of line on the i3500 lcd screen. This
indicates that the maximum load is limited by the
rated strength and the number of parts of line of the
hoist rope. Increasing the number of falls (parts of line)
reeved and set in the display is normally required to
reduce a rope limit.
The Two-Block condition indicator appears near the

crane boom tip depicted on the i3500 lcd screen when
such a condition is detected by the system. This may
block the hoist function, depending on crane model
and/or on the options fitted on the machine.
This indicator appears on the top-left corner of the

i3500 lcd screen, when at least one preset limit is active
on the system. This is not a warning! It is just there to
remind you that an angle, radius or height limit has
been set in the limits setting mode.
One of these indicators appear on the screen when a

preset Maximum or Minimum Angle Limit has
been reached or is about to be reached.
If you are approaching a predetermined maximum or

minimum angle limit, one these indicators will appear
on screen, the approach warning light will blink and the
internal buzzer will turn sound on and off. If you have
reached a predetermined maximum or minimum angle
limit, the overload warning light will be activated and
the buzzer will sound continuously.

i3500 Introduction
This indicator appears on the screen when a preset

Maximum Radius Limit has been reached or is about
to be reached.
If you are approaching a predetermined maximum

radius limit, this indicator will appear on the screen,
the approach warning light will blink and the internal
buzzer will turn sound on and off. If you have reached
a predetermined maximum radius limit, the overload
warning light will light up and the buzzer will sound
continuously.
This indicator appears on the screen when a preset

Maximum Height Limit has been reached or is about
to be reached.
If you are approaching a predetermined maximum

height limit, this indicator will appear on the screen,
the approach warning light will blink and the internal
buzzer will sound on and off. If you have reached a
predetermined maximum height limit, the overload
warning light will light up and the buzzer will sound
continuously.
The zones where the system will warn the operator that a Preset Limit is
being approached can be changed as required. By default these values are
set to: 5 degrees for a min/max angle limit and 2 feet or meters (depending
on the units set at calibration) for a height or radius limit.
In some systems, Limits values are not active when electric power is first
applied to the i3500 and they are automatically disabled if electric power is
removed.
Reaching an operator’s Preset Limit (set in the Limits Setting Mode) will not
result in crane motion cut-off.

i3500 Operation
-3-
Installation & Calibration
Installation of the i3500 system shall be performed by a qualified technician.

Furthermore, calibration of the i3500 system must be performed by a
RaycoWylie certified technician. The RaycoWylie technician will perform a
complete and structured verification of the whole system before beginning the
system’s calibration.
Failure to calibrate the system properly can result in overloading of the

crane risking machine breakage or tipping that could result in serious injury
or death. Always refer to a RaycoWylie certified technician to calibrate
your system.
Installation and calibration manuals are available at

RaycoWylie upon request. Please note that the installation
and calibration instructions have intentionally not been
included in this instruction manual.
-4-
Operating Instructions
4.1 Safety Instructions:
When operating the i3500 system, always observe the safety rules and
regulations applicable in the country of operation to reduce the risk of
personal injury or damage to the equipment. Read the following safety
instructions before attempting to operate this system.
1. The i3500 Rated Capacity Indicator must be properly set-up according to

the crane’s configuration and operating work site situation. Wrong Set-up
can cause the i3500 indicator system to show unreliable information
which may result in hazardous conditions arising such as an overload.
2. The i3500 system is purely an aid to the operator. Responsibility for

the safe operation of the crane lies with the crane operator. The i3500
system will not necessarily prevent crane damage due to overloading
and/or other related causes.

i3500 Operation
3. Proper functioning of the equipment is dependent upon proper daily

inspections and compliance to the operating instructions described in
this manual.

4. During normal operation, the rated capacity of a crane should not be
exceeded. Therefore the overload indication should not be used as a
normal operating feature.
5. The crane should be operated at all times in such a way that the
crane’s motion occurs smoothly and at a safe speed.
6. In order to have the proper rated capacity and radius, the system
must be configured properly. Failure to properly configure the system
can result in machine breakage or tipping which could lead to serious
injury or death.
7. The operator must verify the crane configurations and number of parts
of line for each available hoist every time he/she enters the crane and
every time the crane is rigged.
Note: each hoist has its own configuration set-up kept in memory and
simply by changing the hoist from main to auxiliary the configuration
and number of parts of line will change to suit.
Improper configuration of the i3500 system may also cause a

‘‘Zero Capacity’’ if no chart is found to match the configuration set
by the operator.
4.2 Residual Risks
In spite of the application of all relevant safety regulations and the imple-
mentation of safety devices, certain residual risks cannot be avoided:
• Risks caused by no indication of malfunction of the output relays avoiding

cut off motion to operate in overload conditions, causing machine breakage
or tipping that could result in injury or death.

i3500 Operation
4.2 Residual Risks (cont’d)
• The system gives no indication of the presence of power lines in the crane
working area, causing the risk of operating the crane in the proximity of
power lines that could result in injury or death.
• The system gives no indication whether the outriggers have been fully
extended, causing the risk of machine breakage or tipping that could result
in injury or death.
• The system gives no indication of the crane level, causing risk of machine
breakage or tipping that could result in injury or death.
• System gives no indication of poor ground stability causing risk of machine

breakage or tipping that could result in injury or death.
4.3 Power On
Switch on the electric power (i.e.: crane key switch) to the i3500 system. The
indicator will perform a “Self-test” during which time (approx. 10 sec.) the
audible alarm will sound, the approach, overload and motion cut lights will
illuminate and the display will show the RaycoWylie’s logo. Subsequently, the
i3500 system goes into normal operating mode as shown in Section 2.1 “i3500
normal mode display” of this manual. The normal mode screen allows you to
visualize the Hook load, Rated capacity, Radius, Boom angle, Hoist used, the
Parts of line, etc.

i3500 Operation
4.4 System Configuration
The system configuration is done using the following three key buttons:
Hoist/Scroll up button
Used for hoist selection
Parts/Scroll down button

Used for parts of line (falls) selection.
Duty button
Used for duty number selection.
4.4.1 Duty Number Selection
Carefully read and understand these instructions before selecting a duty

number. Selecting the wrong duty number can result in overloading of the
or death. Never select a duty number if you have any doubts, instead seek the
advice of a qualified technician. Make sure that the duty number displayed in
the normal mode screen matches the current configuration of the machine.

i3500 Operation
4.4.1 Duty Number Selection (cont’d)
Press the Duty button (7) to select a unique duty

number (code) that includes all the configuration
details such as boom/jib, counterweight, outrigger-
/crawler/tyres, hoist etc. The duty number sets all
of the machine parameters in one setting except the
parts of line in use. Refer to the laminated i3500 duty
selection table* supplied with your system for more
details.
* This document is a plasticized sheet of paper and it
must be stored in the operator’s cab for duty selection
purpose.
In case of need of assistance, contact RaycoWylie

with the serial number of your system for technical
advice.
The current duty number is displayed in the upper

right corner of the normal display and additional
configuration information can be seen by pressing
Info button (8).
*Change is not permitted with a load suspended*
Duty number menu

(a) (b)
Fig 1

i3500 Operation
4.4.1 Duty Number Selection (cont’d)
Here you can input a specific duty number in the i3500 system. For example, if
you know that the duty number 57 represents your crane rigged with a 100 ft
boom length, outriggers extended and with a 40 ft jib at 10°, it would be more
convenient to enter the number 57 instead of having to choose each correct
parameters individually. Look up the crane duty number to be used on the
i3500 duty list. The currently selected duty number is displayed in the upper
right corner of the display (see Fig. 1, b).
Changing the crane configuration by

the duty number
1) Press the Duty button (7) to display the duty menu

Note: the duty number should be already highlighted
2) Press Select button (4) to enter the duty

number menu.
or 3) Press Scroll Up or Down button to highlight the

desired number for the first digit (see fig.1, a)
4) Push Select button (4) to confirm your choice.
or 5) Scroll Up or Down to highlight the desired

number for the second digit.
6) Press Select button (4) to confirm your choice.
7) Repeat steps 5 and 6 for the last two digits.
The duty number is a four digit entry. Add leading zeros (0) before the desired
number as necessary. Example: duty#65 = 0065, duty#8 = 0008.

i3500 Operation
4.4.2 Hoist Selection
Carefully read and understand these instructions before selecting the

hoist to be used. Selecting the wrong hoist can result in overloading of the
or death. Make sure that the hoist displayed in the normal mode screen
matches the current configuration of the machine.
The hoist/scroll up button allows the operator to select

the hoist used. The operator can see the hoist selected
on the i3500 screen near the boom base of the crane
drawing (see fig. below).
M = Main Hoist
A = Auxiliary Hoist
1 = Whip 1
2 = Whip 2
To change the Hoist selection:
1) Press Hoist/scroll up ( 2) to automatically change

for the next available hoist.
• In some software versions the hoist selection must be made by using the
Duty button (7). In that case, please note that the direct selection is not
possible using the procedure described here.
• The number of Parts of line, Boom selection and Crane configuration are
associated with each hoist. Therefore, when changing to a different hoist all
of the associated settings for that hoist will be automatically changed.

i3500 Operation
4.4.3 Parts of Line Selection
Carefully read and understand these instructions before selecting the Parts
of line used. Selecting the wrong Parts of line can result in overloading the
rope risking breakage that could result in serious injury or death. Make sure
that the Parts of line displayed in the normal mode screen matches the
current configuration of the machine.
Parts/Scroll down button (3)

This button allows the operator to select the number
of parts of line used.
The operator can

see the current
number of parts
Parts selected just
of Line above the hook
Selection on the on the
Menu i3500 screen.
To change the parts of line selection:
1) Press the Parts/Scroll down button (3) to display

the parts of line selection menu.
2) Scroll up or down with buttons (2) & (3) to

highlight the desired number of parts of line.
3) Push Select button (4) to confirm your choice.

i3500 Operation
4.4.4 System Test
Caution !
The crane must not be in overloading condition when using
the test function.
1) Press Bypass/Rigging (9) and Tare (10) buttons

simultaneously to check the operation of the display,
the audible and visual alarms and the relays
(digital outputs). Some systems will run this test
automatically while others will offer a test menu, if
you see a test menu proceed as follows:
2) Use the Scroll up (2) or Scroll down (3) buttons

to select the function to test.
3) Press Select (4) button to run the desired test. If

the ‘‘button test’’ function is selected, press a
button to see its corresponding number appear on
the screen.
To exit the ‘‘button test’’ do not press any buttons

and the system will automatically return to the test
menu screen.
4) Press Escape (5) button to exit the test menu.

i3500 Operation
4.4.5 System Configuration Information Screen
Simply pressing the Info (8) button is a convenient way to verify the current
configuration of your crane. At a glance, you can check the settings for
numerous parameters such as the outrigger state, boom length, jib selection
etc. If all the data under the chart info screen is correct and if you had
previously set the correct hoist and parts of line number, then your system
should be configured correctly.
Press the Info (8) button repeatedly to display the current crane
configuration.
Press the Escape (5) button to return to the normal mode

screen.
Chart Info Screen
Once your system is properly configured, the

i3500 Rated Capacity Indicator is ready to use.
The chart info screen is different for each crane model. The representation depicted
above may not be identical to the chart info screen shown on your system.

i3500 Operation
4.4.6 System Setup
Choose the
System Set Up
mode
Operating Mode Selection Menu
Numerous display parameters can be configured by the operator.

These parameters are grouped in the system set up mode and they include:
• Language
• Units selection
• Reverse video
• Date & time
Repeat these steps to modify any of the system

setup options, you must first access the system
set up mode:
1) Press the Mode (1) button.
2) Scroll down with the Parts/Scroll down (3) button

to highlight the ‘‘system set up line.
3) Press the Select (4) button to confirm your choice

and enter the desired menu.

i3500 Operation
4.4.6.1 Language Selection
All of the i3500’s text messages can be displayed in

multiple languages: English (default), as specified in
the menu order.
To change the language proceed as follows:
1) Repeat steps 1 to 3 of the preceding section (system

setup options section). Select language.
2) The language line should be highlighted on the

or
display by now. If not, scroll up or down with the
Hoist/Scroll up (2) or Parts/Scroll down (3)
buttons to highlight the desired language.
3) Press Select (4) button to confirm your choice.

i3500 Operation
4.4.6.2 Units Selection
Display
unit menu
It is possible to choose between 5 unit combinations.

Each measure of length and load will be displayed on
the main display.
To change the units proceed as follows:
1) Repeat steps 1 to 3 of the system setup options sec-

tion (see page 29 of this manual). Select units.
2) The Units line should be highlighted on the

or
display by now. If not, scroll up or down with the
Hoist/Scroll up (2) or Parts/Scroll down (3)
button to highlight he desired unit combination.
3) Press the Select (4) button to confirm your choice.

i3500 Operation
4.4.6.3 Reverse Video
Normal display Inverted display
You can invert the colors (black and white) to aid in

viewing the display in various lighting conditions.
To invert the display proceed as follows:
1) Repeat steps 1 to 3 of the system setup options

section (see page 29 of this manual). Select the
Reverse video line.
2) The Reverse video line should be highlighted on

or
the display by now. If not, scroll up or down with
the Hoist/Scroll up (2) or Parts/Scroll down (3)
button to highlight the desired choice.
3) Press the Select (4) to invert the colors accor-

ding to your choice.
4.4.7 Bypass/ Rigging
Warning! When in Rigging mode, the cutoff and overload

alarms are disable. In this condition, the crane is not fully
protected by the i3500, so it’s absolutely essential to obey
the crane manufacturer’s advice regarding lifting the hook
block, slewing or outriggers use.

i3500 Operation
4.4.7 Bypass/ Rigging (cont’d)
The Bypass/Rigging (9) button will be used to

access the following functions: To access the Rigging
Mode, to override an Overload Condition and
to override an ATB condition. The operator can
override the system (lockout) in the event of an emer-
gency by pressing the Bypass / Rigging button. The
Bypass/Rigging button must be pushed again after
15 seconds.
4.4.7.1 Rigging Mode (Maintenance/ Erection Mode)
It is often necessary with many cranes, when stowing or erecting the machine
to go outside the working ‘‘envelope’’ for which the crane manufacturer provides
ratings. For example, the boom stowed position may be outside the maximum
load radius or minimum boom angle specified on any load chart.
For this reason, RaycoWylie systems provide a Maintenance/ Erection mode,
where the boom may be lowered to or raised from the horizontal position without
the external alarm continuously sounding or the motion cut (if fitted) operating.
It is important to note the following points when in rigging mode:
• There are No lock-outs (except for the ATB)

• The ATB switch is still monitored.
• No audible alarms
• The Amber Light is on
• The speeds of the movement are not limited.
• A flashing rigging message is shown on the display.
• The rigging mode can be accessed when the SWL is zero.
The rigging mode is automatically exited when:
• The system is powered off or
• The SWL is greater than zero.

i3500 Operation
4.4.7.2 Overload Override (Bypass)
When overriding the lock-outs during an overload condition, the speeds of the
movements are limited to 15% (25% on some machines) of the permissible
working speed for the corresponding load case. The external alarm and the
external amber and red warning lights are activated. Also, the override
message flashes on the display.
The overload condition can be overridden when:
• The load is above or equal to 100% SWL and

• The load is below 110% SWL and
• A valid duty is selected and the capacity is greater than 0; and
• There are no faulty sensors.
The override is automatically cancelled when:
• The load exceeds 110% SWL or

• The load is below 100% SWL or
• The bypass button is pressed a second time or
• The control levers are in neutral position for more than 10s. or
• There is a faulty sensor; or
• At engine stop or
• An ATB condition occurs or
• The RCI/LMI resets.
4.4.7.3 ATB Condition Override (Bypass)
An ATB condition can be overridden when:
• The system is in rigging mode and

• There is an ATB condition (A2B)
• The ATB override is automatically cancelled when:
• - The bypass button is released; or

• - The ATB condition is cleared; or
• - The Rigging mode is exited.

i3500 Operation
4.4.8 Bridging and Range Limiting Box
OVERRIDE RANGE LIMITING

RESET KEY SWITCH KEY SWITCH
(OPTION)
The Bridging and Range limiting box is a device designed to allow the access
to the range limiting mode as well as other options (see section 4.4.8.2 of this
manual for more details).
4.4.8.1 Bridging device
When the bridging device is activated the crane is no longer protected by

the i3500 system. Therefore, it is absolutely essential to obey the crane
manufacturer’s advice regarding crane operations.

i3500 Operation
4.4.8.1 Bridging device (cont’d)
A bridging device is an embedded electronic mechanism designed to be used in

case of system component failure or in case of emergency. This safety feature
can be accessed through a two-position momentary key switch. A Reset Button
and a Status Led are also provided. (See fig. on section 4.4.8 on page 35).
A bridging device may be provided if it’s located outside of the crane operator’s
cab and it’s under lock and key and it resets automatically at engine stop not
later than 30 min.
Upon activation of the bridging device, the speed of all movements increasing
the loading condition is fixed at 15% max (25% in some machines) of the
permissible working speed for the corresponding load case.
Furthermore, when the bridging device is enabled, the external alarm and the
external warning red light are activated. An override message flashes on the
system display.
The bridging is activated when:
• The momentary switch is turned to the “Indicator override” position.
The bridging is cancelled when:
• The reset button is pressed or

• The engine stops or
• The bridging is active for more than 30 min.

i3500 Operation
4.4.8.2 Bypass / Rigging operation

(Using the Bridging and Range limiting box)
(Refer to section 4.4.8 of this manual)
Reset button:
Press and release the Reset button to cancel the override.
Override Key Switch
General override:
Turn the override key switch to the ‘‘Indicator override’’ position and release
for a complete override. The override indicator will be activated.
Range Limiting Key Switch
Normal Run position:

Normal mode. The system works without a programmed limit.
Slew Range Set position:
This switch position allows access to the Range-limiting mode (refer to section
4.6 of this manual).
Tracks stopped position: This switch position locks the machine tracks
in place to stop it from moving when one or several limits have been pro-
grammed in the system.
This added safety feature is available in option.

i3500 Operation
4.5 Operational Limits Setting
Carefully read and understand these instructions before setting the

Operational Limits. Setting the wrong Operational Limits can result in
accidentally running into obstacles which could lead to serious injury or death.
In the Operational Limits Setting Mode, the operator can set and activate/
deactivate four (4) operational limits in addition to those automatically
provided by the i3500 RCI system. These are as follows:
1) The Minimum Boom Angle Limit.
2) The Maximum Boom Angle limit.
3) The Maximum Boom Tip Height Limit.
4) The Maximum Operating Radius Limit.
Important: Please note that if your machine is

equipped with the Range limiting key switch option,
the Operational Limits setting mode will Not be
available for selection (refer to section 4.4.8 of this
manual for more details).

i3500 Operation
4.5.1 Accessing the Operational Limits Setting Mode
1) Press the Mode button (1) to display the mode

selection menu.
2) Press Parts/Scroll down (3) button once to highlight

the limits setting mode.
3) Press Select (4) button to enter the limits setting menu.
Limits setting Menu
Please note that limits are

not active* when power is
first applied to the i3500
system and they are
automatically disabled if
power is removed.
* Depending on software
version, in some systems
the limits will be kept
active even if power is cut.

i3500 Operation
4.5.2 Limit Value Adjustment
1) Access the Operational limiting mode (refer to

section 4.5.1 for more details).
2) Use the Hoist/Scroll up (2) and Parts/Scroll

or down (3) buttons to highlight the limit you
want to edit.
or 4) Press the Hoist/Scroll up (2) and Down (3)

button to select the desired value for this
particular limit.
5) Press Select (4) button to confirm the selected

value.
6) Press Escape (5) button to return to the

normal operating mode.

i3500 Operation
4.5.3 Enable/Disable a Limit
Limit
Status
1) Access the Operational limiting mode (refer to

section 4.5.1 for more details).
2) Press the Parts/Scroll down (3) button until

the highlighted area moves to the first line of
the column indicated above.
3) Use the Hoist/Scroll up (2) and Parts/Scroll

or down (3) buttons to highlight the current state
(ON or OFF) of the limit you want to activate or
deactivate.
4) Press Select (4) button to toggle between the

ON and OFF state of the limit.
5) Press Escape (5) button to return to the

normal operating mode.
When the value of a given Operational Limit is changed (see section 4.5.2) then,
the modified Limit becomes automatically active.

i3500 Operation
4.6 Range Limiting Option
Carefully read and understand these instructions before setting

the Operational Range Limits. Setting the wrong Operational
Range Limits can result in accidentally running into obstacles
which could lead to serious injury or death.
Crane travel is prohibited when Range Limiting is activated.
The Operational Range Limits settings must be reprogrammed

everytime the crane is moved.
RaycoWylie recognizes that operating cranes in

proximity to power lines or equipment is an extremely
hazardous practice that requires extra precautions. It
is therefore essential to operate the crane outside the
minimum clearances allowed in such a way that there is
no possibility of the crane, load line or load becoming a
conductive path, to avoid the risk of being electrocuted.
The crane shall not be used to handle material stored
under electrical power lines unless any combination
of boom, load, load line, or machine cannot enter the
prohibited zone. The range limiting option provided
by the i3500 system shall not be used to delimit the
prohibited zone. Refer to federal, state, local safety
standards and regulations applicable in your country
regarding operating cranes in proximity to power lines.

i3500 Operation
4.6 Range Limiting Option (cont’d)
Shows which limit Shows which zone is programmed:

is reached: limit high (roof)
RADIUS variable limit height
HEIGHT variable limit radius
WALL free zone (two walls)
RANGE LIMITING WARNINGS:
APPROACH WARNING LIMIT CUT-OFF

OF THE LIMIT REACHED CONDITION
Menu options:
When the system is equipped with the Range Limiting key switch option, the
system automatically selects the Range Limiting mode as the only possible
choice. In that case, the following menu options* are offered:
• High Limit
• Free Zone
• Variable Limit Height
• Variable Limit Radius
* In most systems, only one menu option can be chosen at the time;
however, this may vary depending on software version.

i3500 Operation
4.6.1 Accessing Range Limiting Mode
To access the range limiting mode proceed as follows:
1) Turn the «Range limiting key switch» to the

«slew range set» position (see fig. on section 4.4.8).
2) Scroll down with Parts/Scroll down (3) button

to highlight the range limiting option of your choice.
3) Press the Select (4) button to select one of the

following menu options:
• High Limit
• Free Zone
• Variable Limit Height
• Variable Limit Radius
Menu screen

i3500 Operation
4.6.2 Limit High
1) The «Limit High» option is highlighted by default.

Press Select (4) button to confirm your choice.
2) Boom up to the desired boom tip height limit.
3) Press Select (4) button to confirm the maximum

boom tip height position. As you release Select (4)
button, an 8-second countdown will allow you to
boom down before your programmed height limit
becomes active.
4) To go back to Normal mode, turn the ‘‘Range

limiting key switch’’ to the ‘‘Normal run’’ position or
‘‘Tracks stopped’’ option (if available).

i3500 Operation
4.6.3 Free Zone
VIEW FROM TOP

First wall
Second wall
1) Access the Range limiting main screen menu

(see page 44).
2) Use the Parts/Scroll down (3) button to highlight

‘‘Free zone’’ and press Select (4) button to confirm
your choice.
3) Rotate the crane to the first limit position (first wall).

Press Select (4) button to confirm that this will be
the position of the first wall.
4) Rotate the crane to the second limit position

(second wall). Press Select (4) button to confirm that
this will be the position of the second wall. As you
release Select (4) button, an 8-second countdown
will allow you to rotate the crane between the two
walls before your programmed free zone limit
becomes active.
5) To go back to Normal mode, turn the ‘‘Range limiting

key switch’’ to the ‘‘Normal run’’ position or ‘‘Tracks
Stopped’’ option (if available).

i3500 Operation

4.6.4 Variable Limit Height
1) Access the Range limiting mode (see page 44).
2) Use the Parts/Scroll down (3) button to highlight the

‘‘Variab limit height’’ option.

Press Select (4) button to confirm that this will be the posi-
tion of the first wall.
5) Rotate the crane toward the second limit position (second

wall) with the boom tip always at the maximum height per-
mitted by the surrounding environment. Press Select (4)
button to confirm the position of the second wall. As you
release Select (4) button, an 8-second countdown will allow
you to return between the two walls and boom down below
the height limit before your programmed variable height
limit becomes active.


i3500 Troubleshooting
4.6.5 Variable Limit Radius
1) Access the Range limiting mode (see page 44).
2) Use the Parts/Scroll down (3) button to highlight the

‘‘Variab limit radius’’ option.

Press Select (4) button to confirm that this will be the posi-
tion of the first wall.
5) Rotate the crane toward the second limit position (second

wall) with the boom tip always at the maximum radius per-
mitted by the surrounding environment.
Press Select (4) button to confirm the position of the second
wall. As you release Select (4) button, an 8 second countdown
will allow you to return between the two walls and boom up
within the allowed radius limit before your programmed variable
radius limit becomes active.



5.0 Diagnostic & Troubleshooting
Warning! Troubleshooting shall be performed by a qualified

technician or by an operator with assistance of a RaycoWylie
Service technician.
This section provides technical troubleshooting support. It will address most

frequently asked questions that repair personnel may have when installing,
repairing or performing maintenance on the i3500 system.
5.1 Diagnostic Menu
A diagnostic menu provides information on the sys-

tems status and the state of all connected sensors.
To access the diagnostic menu:
Press Mode (1) button
Use the Hoist/Scroll up (2) or Parts/Scroll down

or
(3) button to highlight your the diagnostic option.
Press Select (4) button to enter the diagnostic menu.
The information provided by the diagnostic menu has been divided into sev-
eral menu pages. Each page applies to one type of sensor at the time or one
particular type of information. The different menu pages available are: angle/
length, load, relay, general info (for a specific type of calibration e.g. telescopic
multi-point), rotation as well as the addresses of all sensors detected by the
i3500 system. Regardless of system configuration, a minimum of three menu
pages are always provided: angle/length, general info and detected addresses.
Additional pages are optional and are only shown if one or more sensors are
enabled (refer to the option enable/disable I/O in the calibration menu).
The use of the Scroll Up/Down arrow buttons will allow the
user to scroll in the menu. When pressing simultaneously on the Scroll Up or
Down arrow button and the key, the display will move from one page to
the next. Pressing the key will show calibration details and also the
original software version of the highlighted sensor.
• This feature is not available for all sensors.
• Pressing the Escape button takes you to the previous menu or

exits the diagnostic mode.

5.2 Angle/ Lenght Sensor
In the diagnostic menu, this is the typical displayed information:
sensor ain 1 ain 2 dr + a2b

Angle 1: 1428 1503 4.99 0
Length 1: 203 N/A 4.99 0
Some applications have more than one angle or length sensor. In this case, all
of the angle sensors are listed first then length sensors will follow. The first
angle sensor to be listed is the one installed closest to the main boom base.
Referring to the example above for the Angle 1 sensor:

Values Ain 1 and Ain 2 vary depending on the inclinometers in the X and in Y
axes that are used to calculate the angle. These values are normally between
1200 and 2900 bits.
Dr + : represents the D.C voltage level of excitation on the angle/ length card
and must be close to 5.00 Volts.
When the multiple reel option is required every angle/length card has an ATB
option that can be activated by dip switch # 4. For the angle/length card,
which is not monitoring the ATB, N/A is shown under a2b instead of 0 or 1,
indicating that it’s not available on this card.
Value 0 represents a safe condition while value 1 will represent a two-block
condition.
As shown on the above table, for the length 1 sensor, the value ain1 represents
the boom extension value in bits. It may vary between around 50 and 975 bits.
The length 1 sensor ain2 value is reserved for future expansion.
Angle 1 and Length 1 sensors are physically located on the same

electronic board.

5.2 Angle/ Lenght Sensor (cont’d)
Press button when “Angle 1” is highlighted to see the software version of

the angle sensor and it’s calibration state. The displayed information will look
similar to this:
Angle 1
ver: 1.01 07 jun 07
d1gx: 823.0 d1gy: 822.0
dzerox: 2041.0 dzeroy: 2034.0
zero angle: -150.2
The line beginning with “ver” indicates the software version of the angle/length
sensor and also its creation date. The next two lines indicate if a sensor has
been calibrated or if the calibration is valid.
D1gx and d1gy must be close to 820 ±1% .
Dzerox and dzeroy must be close to 2048 ±1%.
Zero angle: is the angle in degrees given by the angle sensor when the zero
of the angle has been calibrated on the machine.
To view the software version of the length sensor or it’s calibration state,
press key when Length 1 is highlighted. The displayed information
will look similar to this:
Lenght 1
Ver: 1.01 07 jun 07
Offset: 57
Scale: 0.149661
The line beginning with Ver indicates the software version of the angle/length
sensor and also its creation date. The next two lines indicate if a sensor has
been calibrated or if the calibration is valid. The scale value must be smaller
than 1.0.

5.3 Pressure Sensors
Sensor ain dr+ p1 p2

Load 1 1325 4.96 1 1
Load 2 1109 4.98 1 1
The ain value represents cylinder pressure measured in bits by the pressure
sensor. It can reach a maximum of 4095 bits. The Dr + column is a regulated
D.C. voltage level for the excitation of the pressure sensor and must be close
to 5.00 VDC.
P1 and P2 values indicate the state of proximity sensors (prox 1 and prox 2).
P1 and P2 are used to detect target for the rope direction sensor option, this
option is not available for the telescopic crane pressure sensing, multi-point
version. To know the software version of a pressure sensor or its calibration
state, press when load 1 is highlighted. The displayed information will
look similar to this:
Load 1
Ver: 1.01 07 jun 07
Offset: 373
Scale: 0.1421131
The line beginning with Ver indicates the software version of the pressure
sensor and its creation date. The next two lines indicate if a sensor has been
calibrated or if the calibration is valid. The scale value must be smaller than 1.0.
5.4 Relays
The information shown for the relay cards is divided into two blocks:
The Relay block represents the individual state of every relay. Value “0”
indicates that the relay coil is energized whereas “1” indicates that it’s not
energized. The Inputs block represents the state of the 4 DIN inputs. Value
“0” represents an active input. A maximum of 4 relay cards can be installed.

5.4 Relays (cont’d)
The information shown for the relay board 1 (fig. below) will look similar to
this:
Relay Inputs
Relay 1 2 3 4 5 6 7 8 1 2 3 4
Board 1 1 1 1 1 0 1 1 1 1 1 1 1
The information shown for the relay card EN13000:2010 (fig. below) will look
similar to this:
Press when Relay board 1 is highlighted. The Ver line indicates the
software version of the relay card and its creation date (fig. below).
The displayed Information will look similar to this:
Relay Board 1
Ver: 1.01 07 jun 07

5.5 Slew Sensors (rotation option)
The displayed information will look similar to this:
Note: The informa-

tion depicted here
may differ depen-
ding on the rota-
tion sensor used.
The Ver line indicates the software version of the rotation interface and its
creation date (see fig. above).
rot: Represents the rotation pointer and varies from 0° to 359° (Azimut)
zero pos.: Represents an offset value between the absolute zero and the
relatif zero establish at the moment of calibration .
rot. dir.: Represents the rotation sense.
encoder type: Represents the type of sensor.
5.6 Detected addresses:
This menu page provides the sensor addresses on the CAN network detected
by the i3500 system. Addresses remain in memory as long as the system is
powered even if a sensor stops communicating.
Consult the i3500 Calibration Manual to view additional Diagnostic Menu

pages with information related to internal calibration parameters.

5.7 Error Messages and the use of the key
During start up and other operation processes, the i3500 system analyses all
interactions between internal peripherals (memories, controllers, extension
cards, etc.) and also external ones (physical cards linked to the Canbus network)
5.7.1 Internal Peripherals

If you have any questions or need technical assistance, please contact our
Technical Service Department at RaycoWylie.
Error message Execution process Cause of error

Data logger: Upon startup, the system 1) The Logger card is not
Test failed verifies if the Logger Card installed.
option is activated. 2) The connector has de-
fective soldering
or is broken.
3) There is a problem
with the logger card
Rld flash: When starting system, there 1) There is a problem with

Test failed is a verification (writing/ flash memory (U52)
reading) of the flash chip of
the limit programmed (range
limiting device).
Chart: Upon startup, the system 1) The Load chart chip is not
Test failed does a read verification of installed.
the load chart flash memory 2) Verify the kind of mem-
chip. ory it must be a flash
memory.
3) There is a problem with
flash memory (U12).
Memory bank ‘‘C”: Upon startup, the system 1) There is a problem with
Test failed does a read/write verification EEPROM memory
of bank C EEPROM chip. (U45)
It is to save the system’s
operation parameters. Ex.
winch, number of falls or
parts of line, duty #

5.7.1 Internal Peripherals (cont’d)

Clock: The Logger option must 1) Verify if the black plastic
Test failed be activated. The System cap is installed on the
regularly verifies if the logger card (contains
seconds are moving. If time battery and crystal).
does not change then there 2) There is a problem with
is a problem. the logger card.
Memory bank “A”: Upon startup, the system 1) There is a problem with
Test failed does a read verification of memory EEPROM (U44).
bank A EEPROM chip. It’s
used to save the calibration
data.
RAM: Upon startup, the system 1) There is a problem with

Test failed does a read/write RAM memory (U3). With
verification of RAM Logger option, the cause
chip. This is a volatile is RAM memory (U5).
memory. - if system is behaving
strangely,
- if system initializes often
during operation mode,
- if system never starts.
Not calibrated There is no calibration for the 1) The calibration must be

selected duty. done.
General failure or Can Bus controller 1) There is a problem with

CANbus verification. CANbus controller, either
SJA1000 or MCP2515
(U29).
Multi-languages Verification of programmed 1) The programmed load-

not supp. load chart in the system. chart is not compatible.
Must be multi-languages.
This option can support up
to 10 languages.

5.7.1 Internal Peripherals (cont’d)

External board The Logger option must be 1) The Logger card is not
(Logger) activated. Upon startup, the installed,
system verifies that logger 2) There is a problem
card is present. with one of the two flash
memories.
Low battery on The System detected that the 1) The Logger card’s plastic
data logger Lithium battery is low. This cap must be replaced. It
may cause clock to stop or contains the battery.
lose precision. (See illustration below for
replacement).
No duty The present crane configu- 1) Verify if the load chart

ration is not valid. corresponds to the crane
to be calibrated.
2) Does load chart depend
on rotation?
3) Does load chart depend
on DIN inputs?
No Parameter The Crane dimensions must 1) CL3, CL4 and CL7 values
be entered in the system. should Not be at zero.
The Load value will be null
or wrong.
No 2nd duty found The Comparison angle/ 1) The Load chart must be
radius” option must be programmed for this kind
activated. Thus a jib capacity of application. “One
is evaluated by its angle touch” field is used in the
(offset) against the jib’s chart, load chart for this option.
in comparison to the same
jib’s capacity evaluated by
its radius against the Main
boom chart. The smallest
will be selected.

5.7.2 External Peripherals
A) Angle / Lenght and ATB interface circuit board errors

The i3500 system can support up to 5 angle/length interfaces. Activation of
every angle sensor is done in the calibration menu section ‘‘Enable/Disable
I/O’’.
Angle sensor x defective # The angle sensor value in 1) The Accelerometer or the
volts is not valid (if < 1 volt 12 bits converter is
or > 4 volts). defective.
Length x out of range # A 0xFFFF code is sent by 1) The Length sensor is not
angle/length card to indicate installed
that length sensor is not 2) A wire is cut between
present. length sensor and circuit
board.
Angle x is in Pre-calib. Indicates that angle/length 1) In operation mode, the

card is in pre-calibration jumper must be taken out
mode. from ‘Cal’ jumper located
on the circuit board.
2) Verify that calibration
value in bits of the
accelerometer is valid.
Angle/length Comm # The i3500 system does not 1) The angle/length circuit
receive data from angle sensor. board is defective,
If ‘‘time out’’ delay is reached, 2) The Can bus network
then a communication error cable is broken.
is displayed.
Length x Not calibrated Length sensor is not

calibrated.
Angle Not calibrated Angle sensor is not

calibrated.
Angle/length x Dr+ The 5 volts reference voltage 1) The Angle/length circuit

is not valid (if < 4.5 volts or board is defective.
5.5 volts).

B) Load interface circuit board errors
The i3500 system can support up to 4 load circuit boards. Activation of every
load sensor is done in the calibration menu section ‘‘Enable/Disable I/O’’.

load x out of range The Angle sensor value in
bits is not valid
(if < 150 or > 3935).
load x out not calibrated The Load sensor is not cali-

brated.
load x Dr+ The 5 volts reference voltage The Load card is defective.
is not valid (if < 4.5volts or
> 5.5 volts).
load x Communication The i3500 system does 1) The Load card is
not receive data from defective,
pressure sensor. If “time 2) The Can Bus network
out” delay is reached, then cable is broken.
a communication error is
displayed.
C) Relay and digital input interface board errors
The i3500 system can support up to 4 relay cards. Activation of every relay
card is done in the calibration menu section “I/O activate/deactivate”.

relay x i3500 system does not 1) The Relay card is
Communication receive data from relay defective,
card. If “time out” delay 2) The Can Bus network
is reached, then a commu- cable is broken.
nication error is displayed.
There is no automatic test for the relay contacts on the relay

circuit board. Therefore, if a relay becomes defective there
may not be a warning. Periodically, the operator should test
the lockout system.

D) Generic interface board errors

The i3500 system can support up to 4 generic cards: One for wind speed, one
for inclination level, one for absolute rotation and another one for analogical
output. Activation of every generic card is done in the calibration menu
section ‘‘Enable/Disable I/O’’.

Cant x Not Cal An appropriate, analogical An appropriate, analogical
sensor is not calibrated sensor is not calibrated
Generic Dr + The 5 volts reference voltage 1) The Generic card is
is not valid (if < 4.5 volts or defective.
> 5.5 volts).
Generic The i3500 system does not 1) The Generic card is
Communication receive data from generic card. defective.
If “time out” delay is reached, 2) The Can Bus network
then a communication error
is displayed. cable is broken.
Load x The i3500 system does 1) The Relay card is
Communication not receive data from defective
pressure sensor. If “time 2) The Can Bus network
out” delay is reached, then
cable is broken.
displayed.
E) Rotation interface board errors
Relative rotation
The i3500 system can support only one (1) rotation card. There are two differ-
ent kinds: a relative one and an absolute one. Activation of rotation card is
done in the calibration menu section ‘‘Enable/Disable I/O’’.

Load encoder cable A GND wire indicates 1) Replace cable between
that the cable between the encoder and rotation card.
encoder and the rotation
card is not cut. If the cable
breaks, this wire will become
open. Then the rotation card
will send an error message to
the i3500 system
Encoder ratio No ratio has been entered. 1) Put a different value than 0.
Encoder prox. position. Proximity is not detected in 1) The Proximity is defective.

configured position by i3500
system.
E) Rotation interface board errors (cont’d)

Encoder The proximity switch has 1) The Encoder is defective.
been detected when encoder
did not receive a pulse. On
the other hand, if proximity
is detected at start-up, then
no error is displayed.
Encoder communication The i3500 system does 1) The Rotation card is

not receive anything from defective.
the rotation card. If the 2) The Can Bus network
“timeout” delay is reached, cable is broken.
then a communication error
is displayed.
- Absolute rotation: (a generic card is used for this type of interface)

Encoder ratio Ratio is not programmed. 1) The Encoder is defective.
Encoder Works with serial link RS-422.
Encoder i3500 system does not 1) The Rotation card is

communication receive anything from defective,
rotation card. If “time- 2) The Can Bus network
out” delay is reached, then cable is broken.
displayed.

i3500 Maintenance
-6-
Inspection, Testing & Maintenance
6.1 Frequent Inspections (At the beginning of each shift

during which a crane is used)
• At system power up, check if all alarm lights are on, buzzer sounds and
lockout are activated.
• Verify that the system has been properly configured.
• Verify the accuracy of the clock.
• Verify that no error has been detected by the system.
• Verify the weight of the hook block (must be consistent with last check).
• Verify the radius according to the boom selection. The displayed radius
must be between 0 and 10% greater than the actual radius or in
accordance with current regulations.
• Verify that the capacity displayed conforms to the capacity chart of the
crane manufacturer.
• Verify the functionality of the ATB if fitted.
Warning! Any deficiencies shall be examined and a decision

must be made as to whether they constitute a hazard before
using the machine.
6.2 Periodical inspections (every 6 months)
Inspect at regular intervals the following:
• All cables for cuts or damage as well as all connectors for corroded contacts.
• The attachment of the cable reel at the end of the boom.
• The plunger of the ATB switch for excessive corrosion.
• Excessive wear of brushes in the reeling drum.
• Evidence of leakage at the pressure transducer connection.
• Functionality of the bridging device.
• Operation of the lockout relays.

i3500 Maintenance
6.3 Rated Load Test
• Position and level the machine.

• Testing personnel must be a qualified person for the crane and the i3500’s
system.
• The crane and the system must be configured properly.
• The load chart must be respected.
• A known weight accurate to ± 1% and equal to the maximum capacity at
near maximum radius should be used to test the alarm and the accuracy of
load indication.
• Another known weight accurate to ± 1% and equal to the maximum
capacity at near minimum radius should be used to test the alarm and the
accuracy of load indication.
• Rig with enough parts of line to lift a large weight.
• Measure and record the radius and the hook weight.
• Note the displayed radius, length, hook weight, parts of line and capacity
on the i3500 display unit.
• Lift the large weight.
• Record the actual weight with the hook and rigging attachment.
• Note the average, the low and the high value.
• Perform a hoist up and stop and note the same data.
• Note the actual and displayed radius.
• Lower the load.
• RaycoWylie recommends as a good practice that all test records are
signed and dated, and that a copy of the latest test be available at all
times.

i3500 Maintenance
6.4 Maintenance
Replacement parts must be obtained from

RaycoWylie as original parts, unless approved and
authorized as an equivalent by a Service technician
of RaycoWylie.
Preventive maintenance
• Your i3500 system has been designed to operate over long periods of time
with minimum maintenance. However, continuous satisfactory operation
depends upon system’s care and cleaning.
Important: Do not use pressure steam on the i3500 display box,

junction boxes, angle sensor, load cells or on any connectors.
This could result in moisture in the connectors and can cause
eventual sensor failure.
• To clean the display’s surface, use mild soap or mild window cleaners and
a clean soft cloth.
Important: If condensation appears in the screen of the

display unit, open the cover in a dry place and let it air dry
for a day.
• Replace all cables showing cut or damage or corroded connector contacts.
• Replace reeling drum’s brushes if they show excessive wear.
• Replace ATB switch if the plunger shows excessive corrosion.
• To keep the waterproofness of the i3500’s display the back cover must be
tighten following an X pattern.
• Your i3500 system requires no additional lubrication.

i3500 Maintenance
6.5 Maintenance procedure
Before adjustments and repairs are started on a crane,

the following precautions shall be taken as applicable:
• Place crane where it will cause the least interference with other equipment
or operations in the area.
• Set all controls in the off position and ensure all operating features are
secured from inadvertent motion.
• Render starting means inoperative.
• Lower the boom to the ground, if possible, or otherwise secure against

dropping.
• Lower the load block to the ground or otherwise secure against dropping.
• Relieve hydraulic oil pressure from all hydraulic circuits before loosening
or removing hydraulic components.
• “Warning” or “Out of Order” signs shall be placed on the crane controls and
be removed only by authorized personnel.
• After adjustments and repair have been made, the crane shall not be re-
turned to service until all guards have been reinstalled, trapped air removed
from the hydraulic system and safety devices reactivated. The instructions
shall be provided by the crane manufacturer for the removal of air from
hydraulic circuits.

i3500 Maintenance
6.6 Adjustments and Repairs
• Any hazardous conditions disclosed by the inspection requirements shall

be corrected before operation of the crane is resumed.
Important: Adjustments and repairs shall be done only by

qualified personnel.
• Adjustment shall be made within RaycoWylie’s specified tolerance to

maintain the correct functioning of all components.
• Should you need replacement parts for maintenance and repairs on our
equipments, please contact our Service Department at RaycoWylie.
If you have any questions or need technical assistance, please contact

our Technical Service Department at RaycoWylie quoting the infor-
mation found on the serial number label of your i3500 system.

i3500 Maintenance

i3500 Maintenance
Notes

I3500 Instruction Manual PDF

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

I3500 Instruction Manual PDF

Diunggah oleh

Hak Cipta:

Format Tersedia

55M3500JBE00 Rev B

i3500 Crane information center

Wylie Systems Rayco Electronic Systems Wylie Systems

1020 9th Avenue SW 2440 Dalton Avenue Drury Lane

Tel: (205) 481-2080 Tel: (418) 266-6600 Tel: (+44) 1-424-421235

Rayco Wylie Systems

Authorised Representative: Wylie Systems Manufacturer :

Is in conformity with: The provisions of the Machinery Directive (Directive 2006/42/EC)

This conformity is supposed referring to the following standards,

EN 13000 Cranes – Mobile Cranes

For and on behalf of Wylie Systems, a division of

Telescopic Cranes Pressure Sensing 4 Instruction Manual

The i3500 RaycoWylie Systems Crane Information Center must be regarded

Before operating a crane equipped with a RaycoWylie system RCI, the

Telescopic Cranes Pressure Sensing I Instruction Manual

DANGER: INDICATES A POTENTIALLY HAZARDOUS

CAUTION: INDICATES A POTENTIALLY HAZARDOUS

IMPORTANT: INDICATES A SITUATION THAT MAY CAUSE

NOTE: PROVIDES INFORMATION THAT MAY BE OF

Telescopic Cranes Pressure Sensing II Instruction Manual

1- GENERAL DESCRIPTION OF THE SYSTEM

3- INSTALLATION & CALIBRATION

Telescopic Cranes Pressure Sensing 1 Instruction Manual

4.4.6.1- Language Selection page 30

5.1 Diagnostic Menu page 50

Telescopic Cranes Pressure Sensing 2 Instruction Manual

6- INSPECTION TESTING & MAINTENANCE

6.1- Frequent Inspections page 63

Telescopic Cranes Pressure Sensing 3 Instruction Manual

General Description of the System

This manual contains Operation, Troubleshooting and Maintenance

1.2 Personnel qualification

1.3 Intended use

Telescopic Cranes Pressure Sensing 4 Instruction Manual

1.4 Brief description of the i3500 System

The i3500 is a computerized crane monitoring system, designed as an operator

When wearing ear protection safety devices or

Telescopic Cranes Pressure Sensing 6 Instruction Manual

System with 3 warning lights

Ext Green Amber Red

No event Off Off Off Off Off On Off Off

Telescopic Cranes Pressure Sensing 7 Instruction Manual

System with 1 warning light

No event Off Off Off Off Off Off

Telescopic Cranes Pressure Sensing 8 Instruction Manual

1.5 Typical component location and description

3) Pressure sensors: Highly sensitive, built for precise lifting and

5) Anti-two block: the anti-two block switch is normally closed (with

Telescopic Cranes Pressure Sensing 9 Instruction Manual

1.6 Block Diagram

Block Diagram of the i3500 CANbus

Telescopic Cranes Pressure Sensing 10 Instruction Manual

1.7 Technical Data

Accuracy: In accordance with SAE J159 or EN13000

CANbus sensors / interface: Default quantity Maximal quantity

Telescopic Cranes Pressure Sensing 11 Instruction Manual

Detailed description of the display unit

2.1 Normal Mode Display (default screen)

SLEW PARTS BOOM TIP DUTY

PARTIAL DUTY BOOM ANGLE OPERATING HOOK LOAD SAFE

The display should be used only as a guide, NOT as an

The slew angle indicator (upper left corner of the screen)

Telescopic Cranes Pressure Sensing 12 Instruction Manual

Change is not permitted with a load suspended